Excellent characteristics of multi-walled carbon nanotubes (MWCNTs), such as higher toughness and stiffness, enlarged strength, and high thermal conductivity, make them an attractive choice to improve surface characteristics and machining performance. In the current study, MWCNTs mixed with dielectric fluid in the wire electrical discharge machining (WEDM) process was used to enhance the machining performance of Nitinol shape memory alloy (SMA). Significance of WEDM machining variables such as current, pulse-on time (Ton), pulse-off time (Toff), and variation in powder concentration of MWCNTs are studied on material removal rate (MRR) and surface roughness (SR). The addition of MWCNTs substantially improves the machining performance by increasing MRR and simultaneously reducing the SR. Improvement in the MRR of 75.42% and SR of 19.15% is achieved with the use of MWCNTs at 1 g/L in comparison to the conventional WEDM process. An advanced parameterless TLBO algorithm is used for simultaneous optimization of multiple responses. An advanced parameterless TLBO algorithm is used to find the optimal solution of multiple responses. Single objective optimization result has yielded maximum MRR of 0.5262 g/min at a current of 5 A, Ton 110 μs, Toff 1 μs and MWCNTs amount of 1 g/L while minimum SR of 1.27 μm at a current of 1 A, Ton 1 μs, Toff 24 μs and MWCNTs amount of 1 g/L. MOTLBO algorithm is used for simultaneous optimization of MRR and SR. Lastly, the surface integrity of machined surfaces using a field emission scanning electron microscope (FESEM) is also studied to evaluate the effect of MWCNTs on recast layer thickness (RLT) and other surface defects. The incorporation of MWCNTs has shown a substantial reduction in RLT and other surface defects such as reduction in globules of debris, melted material deposition, micro-crack-free, and micro-pores-free surfaces.

Experimental investigations and optimization of MWCNTs-mixed WEDM process parameters of nitinol shape memory alloy

The multi-layer laser cladding of high temperature resistance alloys i.e., Stellite 6 and Inconel 718 on SS316 was developed with an objective to investigate the effect of cladding materials on clad geometry, microstructure evolution and mechanical properties. The analysis was performed using Optical Microscope, SEM with EDS and Microhardness tester respectively. The results have shown a comparable difference in all the aspects of study. A 50% and 30% increment in clad height is measured while cladding at 12 mm/s and 16 mm/s scan speed as compared to 20 mm/s for both the alloys. The Inconel 718 deposits has shown 15–25% larger clad height, than Stellite 6. Also, under varying process parameters, 15–45% penetration depth and 10–15% higher dilution in Inconel 718 is obtained. SEM results have revealed that the microstructure evolution from top to bottom of the clad is nearly the same except at low laser powers. The decrement in microhardness is observed near the interface due to dilution and is higher in the first layer than the second layer. Whereas, the low dilution obtained in the second layer is because of the newly deposited layer over the substrate. The present work has given the optimum parameters (laser power and scan speed) as 2900 W and 20 mm/s for Stellite 6 and 3400 W, 12 mm/s for Inconel 718 respectively.

Effect of multi-layer laser cladding of Stellite 6 and Inconel 718 materials on clad geometry, microstructure evolution and mechanical properties

https://hal.archives-ouvertes.fr/hal-03670044/document

Numerical investigation of TiO2 and MWCNTs turbine meter oil nanofluids: Flow and hydrodynamic properties

Excellent characteristics of Nitinol shape memory alloys (SMAs) makes them favourable for use in industrial applications. Precision machining of such advanced alloys becomes a key requirement for industrial applications. Conventional machining processes imposes many difficulties for nitinol SMAs. Electrical discharge machining (EDM) process is appropriate for fabricating intricate and complex profile geometries and also provides a better alternative for difficult-to-cut materials. Addition of nano-particles in an appropriate amount in the dielectric fluid improves the machining by producing good dimensional accuracy, higher productivity, and good surface finish for machining of newly developed advanced alloys. The current study investigated the performance of powder-mixed EDM of nitinol SMA with the considerations of design variables of current, pulse-on-time (T on ), nano-graphene powder concentration (PC), and pulse-off-time (T off ) on surface roughness, dimensional deviation (DD), and material removal rate (MRR). Taguchi's L9 (3 ˆ 4) design was employed to perform the experiments and Minitab 17 software was used for statistical analysis of design variables using ANOVA, residual plots, and main effect plots. ANOVA results depicted that PC, T on , and T off were identified to be the highest contributing parameters with 75.18%, 29.37%, and 45.72% to affect MRR, SR, and DD, respectively. Obtained results has depicted a preferred combined positive trend of increase in MRR with a simultaneous drop in SR and DD after the addition of nano-graphene PC. HST algorithm was used to optimize single and multiple responses. Validation trials were also conducted to reveal the ability and suitability of the HTS technique. Field emission scanning electron microscopy revealed the minor occurrence of resolidified debris particles, globules, micro-pores, and micro-cracks after the addition of nano-graphene PC at 2 g/L. 

Machining parameter optimization and experimental investigations of nano-graphene mixed electrical discharge machining of Nitinol Shape memory alloy

Zinc (Zn) is one of the five most widely consumed metals in the world. Indeed, more than 50% of all the zinc produced is used in zinc-galvanizing processes to protect steel from corrosion. Zn-based coatings have the potential for use as a corrosion-resistant barrier, but their wider use is restricted due to the poor mechanical properties of Zn that are needed to protect steel and other metals from rusting. The addition of other alloying elements such as Ni (Nickle) and WC (Tungsten Carbide) to Zn coating can improve its performance. This study investigates, the corrosion performance of Zn–Ni coating and Zn–Ni–WC composite nanocoatings fabricated on mild steel substrate in an environmentally friendly bath solution. The influence of WC nanoparticles on Zn–Ni deposition was also investigated. The surface morphologies, texture coefficients via XRD (X-ray diffraction), SEM (Scanning Electron Microscopy), and EDS (Energy-dispersive X-ray spectroscopy) were analyzed. The electrochemical test such as polarization curves (PC) and electrochemical impedance spectroscopy (EIS) resulted in a corrosion rate of 0.6948 A/min for Zn–Ni–WC composite nanocoating, and 1.192 A/min for Zn–Ni coating. The results showed that the Zn–Ni–WC composite nanocoating reduced the corrosion rate by 41.71% and showed an 8.56% increase in microhardness compared to the hardness of the Zn–Ni coating. These results are augmented to better wettable characteristics of zinc, which developed good interfacial metallurgical adhesion amongst the Ni and WC elements. The results of the novel Zn–Ni–WC nanocomposite coatings achieved a great improvement of mechanical property and corrosion protection to the steel substrate surface.

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Electrodeposition Based Preparation of Zn–Ni Alloy and Zn–Ni–WC Nano-Composite Coatings for Corrosion-Resistant Applications

This paper presents a study on joint strength of adhesively bonded single lap glass fibre reinforced composite (GFRC). Taguchi L27 orthogonal array with four factors (adhesive thickness, overlap length, surface roughness, and adherend thickness) operating at three levels was used for conducting experiments and recorded the failure load and shear strength data. The results reveal that, adhesive thickness being the most dominant and surface roughness has less dominant on failure load and shear strength of composite joints. Multi objective particle swarm optimisation based on crowding distance (MOPSO-CD) was used to optimise the bi-objective functions simultaneously under the input variable constraints. The fitness value obtained for bi-objective functions were found to be close to unity (0.944). The confirmation tests were conducted for optimised conditions to know the appropriateness of MOPSO-CD tool. It has been found that at the optimised conditions the improvement is 52.94% and 61.12% respectively, for failure load and shear strength.

A comprehensive modelling, analysis and optimisation of adhesive bonded single lap glass fibre reinforced composite joints

The development of many engineered product applications for automobiles and aircraft parts has initiated the search for novel materials as alternatives to metal matrix composites (MMCs). Natural-fiber-reinforced polymer composites offer distinct advantages such as biodegradability, eco-friendliness, flexibility, low density, and higher specific strengths, etc. This study focuses on natural-fiber (hemp and banana)-fabric-reinforced polymer composites suitable for exterior-engineered parts. The hand lay-up process is used to fabricate these hybrid composites. Exterior-engineered products are highly susceptible to moisture, which can deteriorate their mechanical performances, including their tensile and flexural strength, thereby affecting the durability of the hybrid composites. Therefore, the hybrid composites are subjected to water absorption tests, where samples are immersed in distilled water for week-long intervals. After each interval, the water-absorbed specimens are tested for their tensile and flexural characteristics as per ASTM D-3039 and ASTM D-790, respectively. The moisture treatment had a notable impact on the composite materials, causing a slight decrease in the tensile strength by 2% due to the diminished lateral strength in the interlaminar fibers. Contrary to expectations, the flexural strength of the composites improved by 2.7% after the moisture treatment, highlighting the potential of the moisture treatment process to enhance the elastic properties of such composites. The dimensions of the specimens changed after the water immersion test, resulting in increased longitudinal and decreased lateral dimensions. The surface morphologies of the composite failure samples showed fiber delamination, fiber breakage, voids, and matrix fractures.

/pdf/physico-mechanical-property-evaluation-and-morphology-study-q4u1hubk.pdf

Physico-Mechanical Property Evaluation and Morphology Study of Moisture-Treated Hemp–Banana Natural-Fiber-Reinforced Green Composites

Computational investigations of aluminum based airfoil profiles of helical shaped vertical axis wind turbines suitable for friction stir joining and processing

Manjunath Patel Gowdru Chandrashekarappa

Papers

A comprehensive modelling, analysis and optimisation of adhesive bonded single lap glass fibre reinforced composite joints

Physico-Mechanical Property Evaluation and Morphology Study of Moisture-Treated Hemp–Banana Natural-Fiber-Reinforced Green Composites

Computational investigations of aluminum based airfoil profiles of helical shaped vertical axis wind turbines suitable for friction stir joining and processing